Prefabricated laminated insulated wall panels

ABSTRACT

Prefabricated insulated wall panels formed from overlying layers of heat resistant materials. The panels are capable of being assembled in abutting relation on the outer surface of a metallic enclosure. The panels have an inner fibrous insulation layer of materials such as asbestos, glass fiber, mineral wool, aluminum silicate fibers or felt secured together with inorganic binders such as bentonite, portland cement or high temperature calcium aluminate cements or an organic binder such as phenolic or latex. The insulation layer has a compressive strength sufficient to afford a suitable working surface. A heat-resistant thermosetting layer formed from an organic adhesive with a base of neoprene, rubber, silicone, or resin adhesive is applied to the insulation layer and bonds a reinforced resin laminate layer formed from polyester, phenolic, or epoxy resin, with glass fiber or fibrous asbestos. The panel joints have bonding strips of several types and configurations securing the resin laminate layer.

United States Patent [72] Inventors Rlehlrd C- Johnson 2,338,801 1/1944Callan i. 138/151 l l i -t 2,778,759 1/1957 Stephens et a1 .4 138/156John M. Connell. Mountain Lake, NJ. 2.874,652 2/1959 Wilson 1. 52/465 X[21] AppLNo. 757,301 3,016,999 1/1962 Glasoe, Jr, 52/267 X [22] FiledSept. 4,1968 3,163,265 12/1964 Waite 52/268 X l Patented July 6,19713,375,628 4/1968 Connell et a1 52/309 [73] Assignee Foster WheelerCorporation FOREIGN PATENTS Livingston, NJ. Continuation of applicafionSen No. 1,443,172 5/1966 France .1 52/309 716,126, Mar. 26, 1968, nowabandoned Pr ary Examiner- Frank L. Abbott which is acontinuation-in-part of Attorneys-John Maier, III, Marvin A. Naigur andapplication Ser. No. 468,819, July 1, 1965, C stantine A. Michalos nowPatent No. 3,375,628.

ABSTRACT: Prefabricated insulated wall panels formed from overlyinglayers of heat resistant materials. The panels are 5 PREFABRICATEDLAMINATED INSULATED capable of being assembled in abutting relation onthe outer WALL PANELS surface of a metallic enclosure. The panels havean inner o Chums, 17 Drawing Figs fibrous nsulation layer of materialssuch as asbestos, glass fiber, mineral wool, aluminum sllicate fibers orfelt secured [52] U.S.C| 52/309, together with inorganic binders Such asbentonite, Portland 52/269 138/151 52/417 52/466 52/622 cement or hightemperature calcium aluminate cements or an [51] Int. Cl E04c 2/22,organic binder such as phenolic or latex The insulation layer E04) 1/80has a compressive strength sufficient to afford a suitable work [50]Fleld of Search 52/309, ing Surfae. A heapresistam thermosening layerformed from 4 1 267 269' 509; an organic adhesive with a base ofneoprene, rubber, silicone, 138/15 or resin adhesive is applied to theinsulation layer and bonds a reinforced resin laminate layer formed frompolyester, [56] References cued phenolic, or epoxy resin, with glassfiber or fibrous asbestos. UNITED STATES PATENTS The paneljoints havebonding strips of several types and con- 2,160,009 5/1939 Walker 138/151X figuratior si s ecuring the resin laminate layer 0 2 Cr v f 20 L 46nz'rs PATENTEDJUL 6B?! 3,590,540

- SHEET 1 OF 3 I N VLiN '1 ()RS JOHN M CON/VELL RICHARD C. JOHNSON ATTORNE Y PATENTEUJUL 619?! FFQU sum 2 BF 3 INVENI'ORS JOHN M. CON/WELLRICHARD C JOHNSON ATTORNEY PATENTEUJUL 6l97| 3,590 54m SHEET 3 [IF 3FIG. 7 INVENTORS JOHN M CON/V6 LL RICHARD C. JOHNSON PREFABRICATEDLAMINATED INSULATED WALL PANELS CROSS REFERENCE TO RELATED APPLICATIONSThe instant application is a continuation of applicants copendingapplication Ser. No. 716,126 filed Mar. 26, 1968, for LaminatedInsulated Wall, (now abandoned) which in turn is a continuation-in-partof copending application Ser. No. 468,819 jointly filed by applicants onJuly I, 1965 for Insulated Wall Construction for Heated Surfaces, nowUS. Letters Pat. No. 3,375,628.

BACKGROUND OF THE INVENTION The present invention provides for theprefabrication of laminated insulated modular components or wall panelswhich may be subsequently assembled to produce an insulated wallconstruction for heated metallic surfaces of the type including steamgenerator fin-tube walls, boiler water wall skin casings or metallicenclosures which contain hot gases as described in U.S. Letters Pat. No.3,375,628. The components of the panels embody advantageous properties,such as compressibility of the fibrous insulation, thermosetting of theouter resin layer which is bonded to the insulation layer, and tensilestrength and modulus of elasticity of the outer laminate of reinforcedresin which is sufficient to compensate for stresses induced by thermalexpansion of the heated surface. Also, the laminate panels of thepresent invention are held together by bonding means such as stripswhich are secured either by adhesive or mechanical means.

An object of this invention is to provide prefabricated insulated wallpanels that can be assembled into a wall construction for enclosingheated metallic surfaces. The wall panels are capable of accommodatingthe expansion and contraction of heated surfaces without rupture of theindividual laminate panels or the jointure between the panels. Thus, thestresses are uniformly distributed throughout the wall construction.

Another'object of this invention is to provide prefabricated laminatewall panels that can be assembled into an insulated wall constructionwhich is weatherproof, strong and resists gouging or scraping.

SUMMARY OF THE INVENTION In accordance with an illustrative embodimentdemonstrating features and advantages of the present invention, there isprovided prefabricated insulated wall panels capable of being assembledagainst the surface of a heated metallic enclosure. The panels comprisean inner fibrous insulation layer formed from a heat resistant materialhaving a compressibility of at least percent under a load ofsubstantially 5 pounds per square inch, a heat resistant thermosettingresin layer or an intermediate adhesive coating, overlying the fibrousinsulation layer, and an outer reinforced resin laminated layeroverlying the therrnosetting resin layer and having a tensile strengthof more than 5,000 psi. and a modulus of elasticity of less than about35x10. Accordingly, the elasticity of the outer reinforced resin layerand the compressibility of the insulation layer is sufficient tocompensate for thermal expansion and contraction of the metallicenclosure. The panels are capable of being secured to the metallicenclosure in abutting relation with the inner fibrous insulation layerof each of the panels contacting the outer surface of the metallicenclosure.

BRIEF DESCRIPTION OF THE DRAWINGS The invention and advantages thereofwill become more apparent upon consideration of the followingspecification and accompanying drawings, in which:

FIG. 1 is a perspective view of a plurality of prefabricated panelsassembled into an insulated wall construction according to an embodimentof the present invention;

FIG. 2 is an enlarged perspective view ofa laminate panel in accordancewith another embodiment of the invention with portions broken away toshow the bonding coating;

FIG. 3 is a perspective view of a wall panel construction havinglaminate panels similar to FIG. 2, but adapted for assembly ontocylindrical surfaces, with the combined wall panel shown prior to beingassembled onto the cylinder;

FIG. I is a transverse section through a cylindrical pipe on which thereis mounted the wall panel construction of FIG. 3;

FIG. 5 is a transverse sectional view of the wall panel constructionshown in FIG. 2;

FIG. 6 is a perspective view of another embodiment of a laminate panelsimilar to the panel of FIG. 5, but showing a reinforcement bararrangement and the laminate panels assembled into a wail construction;

FIG. 7 is a transverse sectional view through a portion of the panelsshown in F IG. 6;

FIG. h is a transverse sectional view of a laminate panel constructionsimilar to the panel of FIG. 2 in which extruded bonding means areprovided;

FIG. 9 is a transverse sectional view of another embodiment of a panelconstruction for use with cylindrical pipes;

FIG. 10 is a perspective view of the panel shown in FIG. 9;

FIG. Ill is a transverse sectional view of assembled laminate panelssimilar in construction to the panel shown in FIG. 2, with the panelsheld in abutting relation by a strip member;

FIG. I2 is a transverse sectional view similar to FIG. II, but with thepanels held in abutting relation by means of a lap joint;

FIG. I3 is a transverse sectional view similar to FIG. Ill, but with thepanels held in abutting relation by means of a doublebutt strip member;

FIG. 14 is a transverse sectional view similar to FIG. II, but with thepanels held in abutting relation by means of preformed angle stripmembers;

FIG. I5 is a transverse sectional view similar to FIG. II, but with thepanels held in abutting relation by means of a rivetted strip member;

FIG. 16 is a transverse sectional view similar to FIG. 11, but with thepanels held in abutting relation by means of rivetted double stripmember; and

FIG. 17 is a transverse sectional view similar to FIG. 11, but with thepanels held in abutting relation by means of staples.

DESCRIPTION OF THE PREFERRED EMBODIMENTS As shown in the drawings, theouter surface of a heated metallic enclosure such as a steam generatorwall 10, formed from parallel tubes 112 connected by intermediate fins14, provides a gastight construction or enclosure for a steam generatorfin-tube pressurized chamber.

With reference to FIG. I, in accordance with the present invention thereis provided a combined-panel wall 16 of individual prefabricatedlaminate panels It which are attached to the outer surface of steamgenerator wall 10. The laminate panels Ml comprise an inner fibrousinsulation layer 20, a heat-resistant thermosetting layer 245, and anouter reinforced resin laminate layer 28. The thermosetting layer 2a iscoextensively disposed between insulation layer 20 and resin laminatelayer 2%, and serves as a means of bonding together layers 20 and 28.

The fibrous insulation layer 20 is formed from material oflowconductivity such as asbestos, fiber glass, mineral wool, aluminumsilicate fibers, or felt which are secured together with an inorganicbinder such as bentonite, Portland cement, or high temperature calciumaluminate cements or an organic binder such as phenolic or latex. Thethickness of insulation layer 20 may vary from one eighth inch togreater thicknesses dependent on a given setting. An importantcharacteristic of the fibrous insulation layer 20 is that it be formedfrom resilient material having a high enough compressive strength toafford a suitable working surface which will prevent compressive failureof the insulation. The compressibility of the material forming thefibrous insulation layer 20 should preferably be at least 15 percentunder a load of 5 pounds per square inch. As best shown in FIG. I, thethermosetting layer 2 1 is bonded to, and reinforced in part, by thefibers of insulation layer 20. The thermosetting layer 26 is formed froman organic adhesive with a base of neoprene, rubber, silicone, or resinadhesive. The reinforced resin laminate layer 23 is formed from a fiberglass reinforced resin or an inorganic material such as sodium silicate.The reinforced resin laminate layer 28 must have a tensile strength ofrnore'than 5,000 p.s.i. and a modulus of elasticity of less than 35X l".The modulus of elasticity of resin laminate layer 2?? and thecompressibility of the fibrous insulation layer 2&3 are sufficient tocompensate for thermal expansion and contraction of the metallicenclosure and/or structural members associated with the wall, such asdoors, piping, insulation and laminate anchors or supports. The resinlaminate layer 28 is fabricated from polyester, phenolic, or epoxyresin, with fiber glass reinforcement or fibrous asbestos or otherfillers. The preforming of the insu lated wall construction H6 ispreferably fabricated from assembling individual laminate panels l8,having typical dimensions such as 2X3 feet, or 4X8 feet.

As shown in FIG. l, the prefabricated laminate panels M are held tosteam generator wall Elli by means of flat-head anchors 34. Theprefabricated laminate panels 18 are assembled to steam generator wallllll in abutting relation and form jointures 36 between the panels l8which are adjacent to each other. Bonding means 3% formed from materialsimilar to that or resin laminate layer 2?, are secured along jointures36.

In FIGS. 2 and 3 there is illustrated a further embodiment of theinvention in which corresponding parts have been designated by the samereference numerals as part of a 100 series. In this form of theinvention a combined panel wall 1116, as shown in FIG. s, is assembledfrom laminate panels 111%. The laminate panel llllh comprises a fibrousinsulation layer 120 the outer surface of which is sprayed with anadhesive coating R24, and a reinforced resin laminate layer Mb. Thefibrous insulation layer 12d is bonded to resin laminate layer i128 bymeans of the adhesive coating 1124 which is absorbed into the outersurface of insulation layer LZll. The adhesive coating 1124 ispreferably formed from epoxy cement or an organic cement. The layersll2ll and E28 are fabricated from materials which are respectivelysimilar to, and have the same physical properties, as fibrous insulationlayer 24), and resin laminate layer 25;.

Turning to H618. s and '7, the insulated wall construction M6 is shownassembled by means of reinforcement bars lll which are positionedbetween adjoining laminate panels 118. The fibrous layer 1124) is formedwith cutout channels 152 which are overlapped by a portion of resinlaminate layer 1128, such that reinforcement bars 115 9 can beaccommodated and enclosed when the laminate panels ll?) are brought intoadjoining relationship. When the reinforcement bars 150 have beenpositioned in the spaces formed by pairs of adjoining channels 152, itis possible to apply an epoxy cement and bonding tapes 3&3 are securedalong the outer surface of layer 128 at the jointures 36. Thereinforcement bars 115th also act as a means of preventing radiationfrom passing through the jointures 36.

The laminate panels Hill are shown a modified form in FIGS. 3 and 4, foruse in connection with the insulation of cylindrical structures, inwhich corresponding parts have been designated by the same referencenumerals as part of a 200" series. Accordingly, FlG. 3 shows a combinedpanel wall 216, in sheet form, integrally formed from laminate panels21m. The sheet form ofpanel construction 2116 comprises a series ofcoextensive fibrous layers bonded by means of an adhesive coating 224 toa continuous sheet of resin laminate layer 228. The laminate panels 218are formed from materials which correspond to the material of laminatepanels 118, and have the same physical properties thereof. Between thepanels 2H8 which adjoin one another, are rectangular-shape jointurechannels 236, which allow for the wall sheet construction 216 of FIG. 2to be secured around a cylindrical pipe 238, as shown in FIG. 4. Sincethe jointure channels 236 are located between the individual laminatepanels 2M3, it is possible to bring the adjacent edges of fibrous layers220), on adjoining panels 218, into abutting contact, when assemblingwall sheet construction 2M5 to cylindrical pipe 238.

In FIGS. 9 and 10 a cylindricalwall sheet construction 216 is shownhaving a premolded annular shape, rather than the flat configuration ofFIG. 2. Accordingly, the premolded wall sheet 216 is formed with a slitopening 240 which extends through fibrous insulation layer 220, coating224, and resin laminate layer 228. Due to the resiliency of cylindricalwall sheet construction 216, it is possible to spread apart slit opening240 for assembly onto cylindrical pipe 238.

in FIGS. 8 and ll through 17, various embodiments of bonding means 38are shown in detail. Thus, FIG. 8 shows bonding means 38 in the form ofa preformed extrusion 2 60 having a frustoconical-shaped central channel262 and a pair of grooves 264 on opposite sides of channel 262. Thepreformed extrusions 260 are used to assemble the laminate panels intothe combined panel wall 116 by depositing a bonding agent such as anepoxy cement or inorganic cement in grooves 264. In this manner, thepreformed extrusion 260 can be secured to the outer surface of resinlaminate layer 128 along the jointures 36. The flat head anchors 34 arereplaced by arcuate-head anchors 266 which can be snap fitted intochannel 262 for mounting the combined panel wall 116 onto the steamgenerator wall ill.

As best shown in FIG. 11, the bonding means 38 is in the form of a stripmember 270 which is secured to the outer surface of resin laminate layer128 along the jointures 36. It is preferable to use an epoxy orinorganic cement to secure strip member 270 to laminate layer 128. Thematerial ofstrip members 270 is the same as that of resin laminate layer128.

In FIG. E2, the laminate panels 113 are assembled by means oflap joints272. The laminate panels 118 of FIG. 12 include a lap panel M9 and flushpanel 121. The lap panel 119 is formed with edge portions 274 onlaminate layer 128 which extend over the edges of insulation layer 120.The flush panel U1 is substantially identical in configuration tolaminate panel lid of FIG. 2, but the flush panel 121 is formed with anoverall thickness which is equal to the thickness of insulation layer1124) of lap panel 119. This dimensioning of panels 119 and 1121 allowsfor a uniform surface, on the edge of wall panel M65, as shown in FIG.112. By surrounding each lap panel 119 with four flush panels 1121, itis possible to achieve an integrally formed combine panel wall 1 16 byapplying a bonding agent such as epoxy cement to lap joints 272.

Turning to FIG. 13, there is shown the laminate panels 118 which arejoined together by means of a double-butt strip 278. The fibrousinsulation layer 1120 is provided with a cutout channel 122 foraccommodating butt strip 78, and the outer edge of laminate layer 128overlies channel 122. Accordingly, the butt strip 278 is formed with anill-shaped cross section with opposing notches 289. To assemble laminatepanels 118 with the butt strips 278, the base portions of butt strips278 are mounted in cutout channels i122 and the edges of laminate layer112%} are positioned in the notches 280. In this manner, an epoxy cementcan be used for joining together the panels 1 18.

Referring now to FIG. 14, there is shown preformed angle strips 282 forassembling the laminate panels 118 into combined panel wall 116. Theangle strip 282 has an L-shape cross section and includes a horizontalarm 28 i, integrally formed with a vertical arm 286. The laminate panels118 are assembled by mounting pairs of angle strips along the edges ofabutting laminate panels 118. Thus, for each pair of angle strips 282,the horizontal arms 284 are bonded along the surface edge oflaminatelayer R28 and the vertical arms 286 are bonded together. It ispreferable to use an epoxy-type cement for bonding the angle strips 282together, as well as joining strips 282 to laminate panels 118.

In FIG. 15 the laminate panels 1 .18 are held in abutting relation bymeans of a rivetted single strip member 288. The single strip member 288is mechanically bonded along jointure 36 by means of a pair of rivets290.

With regard to FIG. l6, there is shown a rivetted double strip member292, which includes a lower strip 293 and an lower strip 293 along theouter surface of resin laminate layer I 128. A pair of rivets 295 areinserted through the upper strip 294, laminate layer 128 and lower strip293, to mechanically bond laminate panel 118.

Turning to FIG. 17, the panels 118 are held in abutting relation bymeans of staples 296. Thus, a mechanical bond is established byinserting the staples 296 through the panels 118 which adjoin eachother.

A latitude of modification, change and substitution is intended in theforegoing disclosure and in some instances some features of theinvention will be employed without a corresponding use of otherfeatures. Accordingly, it is appropriate that the appended claims beconstrued broadly and in a manner consistent with the spirit and scopeof the invention herein.

What we claim is:

l. Prefabricated panels capable of being assembled into an insulatedwall construction for a heated metallic enclosure comprising: an innerfibrous insulation layer'formed from a heat resistant material having acompressibility of at least percent under a load of substantially 5pounds per square inch, a heat resistant thermosetting resin layeroverlying said fibrous insulation layer, and an outer reinforced resinlaminate layer overlying said thermosetting resin layer and having atensile strength of more than 5,000 p.s.i. and of a modulus ofelasticity less than about 3.5 l0 such that the elasticity of said outerreinforced resin layer and compressibility of said insulation layer issufficient to compensate for thermal expansion and contraction of saidmetallic enclosure, said panels being capable of being secured to saidmetallic enclosure in abutting relation with said inner fibrousinsulation layer of each of said panels contacting the outer surface ofsaid metallic enclosure.

2. Prefabricated panels according to claim 1, in which jointures areformed between said panels which are in abutting relation, and meansdisposed along said jointures for continuously connecting said insulatedwall construction.

3. Prefabricated panels according to claim 11, in which saidthermosetting resin layer is reinforced by the fibers of said fibrousinsulation layer and said thermosetting resin layer is coextensivelypositioned on the exposed side of said fibrous insulation layer.

4. Prefabricated panels according to claim 1, in which saidthermosetting resin layer is reinforced by the fibers of the fibrousinsulation layer, said thermosetting resin layer covering the exposedside of said fibrous insulation layer and said reinforced resin laminatelayer applied over said thermosetting resin layer thereby forming saidlaminate panels with a resiliency selected to compensate for thermalexpansion of said metallic enclosure.

5. Prefabricated panels according to claim I, in which said fibrousinsulation layer, said thermosetting resin layer and said resin laminatelayer are formed into .a concentric cylindrical wall configuration.

6. Prefabricated panels according to claim 1, in which saidthermosetting resin layer and said resin laminate layer are formed froma polyester resin and said fibrous insulation layer is formed from amaterial of the class consisting of fibers of asbestos, glass, mineralwool, and aluminum silicate, together with a binder of the classconsisting of calcium aluminate, P01 tland cement, phenolic and latex.

7. Prefabricated panels according to claim 1, in which said panels aresecured on the outer surfaces of said metallic enclosure with saidfibrous insulation layer, thermosetting resin layer, and resin laminatelayer of each of said panels, positioned in juxtaposed relation to formjointures between said panels.

8. Prefabricated panels according to claim 7 in which bonding meansextend along the length of said jointures for joining ,said anelstogether.

9. refabrrcated panels according to claim 8, in which said bonding meansare formed from strips secured to said panels at said jointures and saidstrips fabricated from material having physical properties similar tothe physical properties of said reinforced resin laminate layer.

10. Prefabricated panels according to claim 9, in which said strips areformed with a uniform cross section.

2. Prefabricated panels according to claim 1, in which jointures areformed between said panels which are in abutting relation, and meansdisposed along said jointures for continuously connecting said insulatedwall construction.
 3. Prefabricated panels according to claim 1, inwhich said thermosetting resin layer is reinforced by the fibers of saidfibrous insulation layer and said thermosetting resin layer iscoextensively positioned on the exposed side of said fibrous insulationlayer.
 4. Prefabricated panels according to claim 1, in which saidthermosetting resin layer is reinforced by the fibers of the fibrousinsulation layer, said thermosetting resin layer covering the exposedside of said fibrous insulation layer and said reinforced resin laminatelayer applied over said thermosetting resin layer thereby forming saidlaminate panels with a resiliency selected to compensate for thermalexpansion of said metallic enclosure.
 5. Prefabricated panels accordingto claim 1, in which said fibrous insulation layer, said thermosettingresin layer and said resin laminate layer are formed into a concentriccylindrical wall configuration.
 6. Prefabricated panels according toclaim 1, in which said thermosetting resin layer and said resin laminatelayer are formed from a polyester resin and said fibrous insulationlayer is formed from a material of the class consisting of fibers ofasbestos, glass, mineral wool, and aluminum silicate, together with abinder of the class consisting of calcium aluminate, Portland cement,phenolic and latex.
 7. Prefabricated panels according to claim 1, inwhich said panels are secured on the outer surfaces of said metallicenclosure with said fibrous insulation layer, thermosetting resin layer,and resin laminate layer of each of said panels, positioned injuxtaposed relation to form jointures between said panels. 8.Prefabricated panels according to claim 7 in which bonding means extendalong the length of said jointures for joining said panels together. 9.Prefabricated panels according to claim 8, in which said bonding meansare formed from strips secured to said panels at said jointures and saidstrips fabricated from material having physical properties similar tothe physical properties of said reinforced resin laminate layer. 10.Prefabricated panels according to claim 9, in which said strips areformed with a uniform cross section.